101603-7651 ZEXEL 9 400 615 203 BOSCH INJECTION-PUMP ASSEMBLY 9400615203 1016037651 1156026932

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 615 203 9400615203

ZEXEL 101603-7651 1016037651

ISUZU 1156026932 1156026932

Service parts 101603-7651 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6000

3. GOVERNOR 105931-8281

4. SUPPLY PUMP 105220-5930

5. AUTOM. ADVANCE MECHANIS 105644-0470

6. COUPLING PLATE 105661-0730

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-7114

11. Nozzle and Holder 1-15300-279-2

12. Open Pre:MPa(Kqf/cm2) 16.2{165}/18.1{185}

13. NOZZLE-HOLDER 105048-3883

14. NOZZLE

15. NOZZLE SET 105019-1490

Include in #1:

101603-7651 as INJECTION-PUMP ASSEMBLY

Include in #2:

104740-1870 as _

Cross reference number

BOSCH 9 400 615 203 9400615203

ZEXEL 101603-7651 1016037651

ISUZU 1156026932 1156026932

Zexel num

Bosch num

Firm num

Name

101603-7651

9 400 615 203

1156026932 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1-S K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 132424-0620

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.6 3.55 3.65

Rack position
After adjusting injection quantity. R=A

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 11

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 71.5 69.9 73.1

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point -

Rack position 9.6+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 9.4 8.1 10.7

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 71.5 70.5 72.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.2

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 81 77 85

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 100 100 132

Fixing the lever *

Timer adjustment

Pump speed r/min 1275

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1500

Advance angle deg. 5.5 5 6

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=J71
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=42deg+-5deg b=(43deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=25deg+-5deg b=40deg+-5deg

0000001501 I/P WITH LOAD PLUNGER ADJ

Plunger assembly number: PL (stamping: ST) 1. Adjustment procedures (1)Insert the pre-stroke adjusting shims L1 for each cylinder. (2)Adjust injection quantity.(max. var. bet. cyl. idling a1, full a2) (3)At basic point A, adjust so that the pre-stroke is L2. (4)Reconfirm the injection quantity.
----------
PL=131153-6420 ST=A743 L1=1mm L2=3.6+-0.05mm a1=+-14% a2=+-2.5%
----------

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)At rack position = bb
----------
aa=8deg bb=R1(11)mm
----------
a=(60deg)